Lightweight clumping animal litter and method thereof

Abstract

Animal litter having up to a sixty percent reduction in bulk density can be produced by combining flat-shaped cellulosic materials and sodium bentonite clay. Not only is the resulting litter lighter, but it also maintains a high clump strength as compared to clay-based animal litters that contain greater than ninety percent by weight sodium bentonite clay.

We claim: 
     
       1. Composite particles suitable for use as an animal litter comprising:
 a flat-shaped cellulosic material component having a mean particle size ranging from 0.2-3 mm and having an aspect ratio of at least 2; 
 a powdered sodium bentonite component having a mean particle size less than 0.25 mm;
 wherein the ratio of cellulosic material to sodium bentonite ranges from 1:4 to 4:1 and wherein the mean particle size of the composite particles ranges from 0.4-4 mm; and 
 wherein the composite particles when used as an animal litter have a clump strength of at least 80%. 
 
 
     
     
       2. The composite particles recited in  claim 1  further comprising a spacer material having a mean particle size less than 0.25 mm. 
     
     
       3. The composite particles recited in  claim 1  further comprising a binder having a mean particle size less than 0.25 mm. 
     
     
       4. The composite particles recited in  claim 1  further comprising a spacer material having a mean particle size less than 0.25 mm and a binder having a mean particle size less than 0.25 mm. 
     
     
       5. An animal litter comprising a dry blend of:
 (i) composite particles comprising
 (a) a flat-shaped cellulosic material component having a mean particle size in the range of 0.2-3 mm; where the aspect ratio is at least 2 
 (b) a powdered sodium bentonite component having a mean particle size less than 0.25 mm, wherein the ratio of cellulosic material to sodium bentonite is in the range of 1:4 to 4:1 and wherein the mean particle size of the composite particles is in the range of 4-0.4 mm; 
 (c) optionally a spacer material, and 
 (d) optionally a binder; 
 
 (ii) granular sodium bentonite having a mean particle size in the range of 0.4-2 mm; and 
 (iii) optionally granular calcium bentonite having a mean particle size in the range of 0.4-2 mm; 
 wherein the animal litter has a clump strength of at least 80%. 
 
     
     
       6. The composite particles recited in  claim 5 , wherein the spacer material is selected from the group consisting of PAC, silica gel, zeolite, calcium bentonite, limestone, gypsum, kaolinite, silica, hydrophobic silica, flow aid such as talk, starches and combinations thereof. 
     
     
       7. The composite particles recited in  claim 5 , wherein the binder is selected from the group consisting of guar gum, modified starch, natural hydro-coloids, alginates, acrylates, poly vinyl acetate, and combinations thereof. 
     
     
       8. A method of making composite particles having a cellulosic material component and a sodium bentonite component comprising:
 providing flat-shaped cellulosic particles having a mean particle size ranging from 0.2-3 mm; 
 providing powdered sodium bentonite particles having a mean particle size less than 0.25 mm, wherein the ratio of cellulosic material to sodium bentonite is in the range of 1:4 to 4:1; 
 using a high shear agglomeration process to mix the cellulosic particles and the sodium bentonite particles to form composite particles having a mean particle size in the range of 0.4-2 mm.